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Advanced Vehicle Technologies (AVT), a Ballarat Australia based company, has developed the World's first diesel to 100% LPG conversion for heavy haul trucks. There is no diesel required or utilized on the trucks. The engine is converted with minimal changes into a spark ignition engine with equivalent power and torque of the diesel. The patented technology is now deployed in 2 Mercedes Actros trucks. The power output in engine dynamometer testing exceeds that of the diesel (in excess of 370 kW power and 2700 Nm torque). In on-road application the power curve is matched to the diesel specifications to avoid potential downstream power-train stress. Testing at the Department of Transport Energy & Infrastructure, Regency Park, SA have shown the Euro 3 truck converted to LPG is between Euro 4 and Euro 5 NOx levels, CO2 levels 10% better than diesel on DT80 test and about even with diesel on CUEDC tests.

The demand for improved fuel economy in both cars and trucks has emphasized the need for lighter weight components. The application of high strength steel to wheels, both rim and disc, represents a significant opportunity for the automotive industry. This paper discusses the Ranger HSLA wheel program that achieved a 9.7 lbs. per vehicle weight savings relative to a plain carbon steel wheel of the same design. It describes the Ranger wheel specifications, the material selection, the metallurgical considerations of applying HSLA to wheels, and HSLA arc and flash butt welding. The Ranger wheel design and the development of the manufacturing process is discussed, including design modifications to accommodate the lighter gage. The results demonstrate that wheels can be successfully manufactured from low sulfur 60XK HSLA steel in a conventional high volume process (stamped disc and rolled rim) to meet all wheel performance requirements and achieve a significant weight reduction.

The Clean Air Act Amendments of 1990 have brought about wholesale changes in the mandated requirements for the EPA and states to bring clean air to the country. Of particular interest to the light and heavy duty truck and bus industry are the requirements for VOC reductions in Title I, the hazardous pollutant reductions requirements in Title III, and the new permitting scheme required under Title V of the Act. The inter-relationship of lower VOC coatings, hazardous pollutant reduction, and permitting requirements will be presented. Since the Act does not fully mesh these requirements, the pathways that coating suppliers and coating application facilities can use to come into compliance will be explored. Specific VOC content of conforming coatings will be presented, how they will impact application processes, and how hazardous air pollutant reductions can be achieved is explored.

The in-cylinder direct injection of fuels can be a further step towards cleaner and more efficient internal combustion engines. However, the injector design and its characterization, both experimental and from numerical simulation require accurate diagnostics and efficient models. This work aims to simulate the complex behavior of the gaseous and liquid jets through an outwardly opening injector characterized by optical diagnostics using a one-dimensional model without using three dimensional models. The behavior of the jet from an outwardly opening injector changes according to the type of fuel. In the case of the gas, the experimental investigations put in evidence three main jet regions: 1) near-field region where the jet shows a complex gas-dynamic structure; 2) transition region characterized by intense mixing; 3) far-field region characterized by a fully developed subsonic turbulent jet.

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Three-dimensional transient simulation was performed and an autoignition model was implemented to predict knock occurrence and autoignition site in a heavy-duty liquefied petroleum gas (LPG) engine. A flame area evolution (FAE) premixed combustion model was applied to simulate flame propagation. Engine experiments using a single-cylinder research engine were performed to calibrate the reduced kinetic model and to verify the result of this modeling. A pressure transducer and a head-gasket type ion-probe circuit board were installed to detect knock occurrence, flame arrival angle, and autoignition site. The simulation result shows good agreement with engine experiments. It also provides much information about in-cylinder phenomena and some ways to reduce knocking tendency. This knock simulation can be used as a development tool of engine design.

Organized in cooperation with SAE International, AVL’s International Commercial Powertrain Conference- ICPC, happens every two years. This event offers a unique opportunity for engineers to address the synergy effects and distinctive characteristics of commercial vehicles, agricultural tractors and non-road vehicles, and industrial machinery. In 2015, the 8th ICPC focused on alternative powertrain technologies and innovations improving operating efficiency. These proceedings include 17 papers focusing on the following topics: • Emissions reduction for heavy-duty vehicles • Alternative drivetrains • Autonomous driving • Connected driving • Efficiency • Alternative fuels • Product diversity • Challenges of cost vs. complexity

A pin and disc machine has been modified for the evaluation of silver-steel lubrication characteristics of railroad diesel oils. Use of silver pins on polished steel discs at selected loads and rubbing speeds allows good correlation with known engine behavior. In comparison with wear and friction data obtained by the four ball method, this pin and disc test gives better correlation with engine tests than the Modified Four Ball Test.

Engine mounts are an integral part of the vehicle that helps in reducing the vibrations generated from the engine. Engine mounts require a simple yet complicated amalgamation of two very different materials, steel and rubber. Proper adhesion between the two is required to prevent any part failure. Therefore, it becomes important that a comprehensive study is done to understand the mating phenomenon of both. A good linking between rubber and metal substrate is governed by surface pretreatment. Various methodologies such as mechanical and chemical are adopted for the same. This paper aims to present a comparative study as to which surface pretreatment has an edge over other techniques in terms of separation force required to break the bonding between the two parts. The study also presents a cost comparison between the techniques so that the best possible technique can be put to use in the commercial vehicle industry.

This paper describes the results of a series of fatigue studies relating the lives of several weld geometries. Rotating beam and axially loaded specimens were used. A comparison between steel and plastic (polyvinylchloride scale models is made. Using plastic scale models of welded structures for fatigue life determination is the ultimate goal of this work.

“Today, wearing parts are regularly subjected to abnormal loading conditions. They must be able to accept these conditions without failure. In continuous operations, unscheduled downtime greatly increases maintenance costs, not to mention the cost of lost production. White iron castings offer premium abrasion resistance for many of these applications, but are often not used due to the possibility of brittle failure and the difficulty of mechanical attachment. This paper discusses the properties and applications of a composite of martensitic white iron and mild steel. This laminate will accept medium to high impact without loss of service failure, and can be installed by mechanical means or with welded attachment.”

This paper describes the conversion of a stationary spark ignition engine to a heavy duty (HD) natural gas engine suitable for transportation applications, in response to the new urban truck and bus legislation of 1994 and 1998. The approach to the fuel and ignition control system is to use a microprocessor controlled engine management system based on inputs from combustion air and natural gas mass flow sensors. As the emission control system is also based on stoichiometric three way catalyst technology, it is felt that the control approach is very robust. The engine and control system were first mounted on a HD dynamometer for the development work where engine control parameters were calibrated. In addition steady state emission data were collected and estimates of the HD transient emission levels were obtained.

This paper describes the simulation model of a backhoe excavator. The model uses a prescribed motion cycle and the objective of the program is to determine the power requirements for each of the cylinders as well as the total engine power requirement. Most computer simulations are developed by expressing the differential equations of motion for the system being studied. The known force inputs to the system are applied and the time response of the system is then obtained by numerically integrating the governing differential equations. This paper on the other hand develops the reverse of this. Utilizing a prescribed geometry and trajectory cycle for a linkage system as the input, the program solves for the types of force inputs that are required to achieve that trajectory. With the time dependence of the trajectory known, the total power required and the power required of each cylinder is also evaluated. A typical excavator linkage is shown in Fig. 1.

This paper presents the results of a two-phase Philippine study to determine the actual mileage (km/liter) of in-use diesel and LPG (liquefied petroleum gas or Auto-LPG) public utility jeepneys plying two separate Metro Manila urban routes using both on-road and chassis dynamometer tests. Measured average load factor in on-road tests was 60-70%. Dynamometer tests at 100% load factor utilized drive cycles derived from on-road speed data. A “diesel equivalent mileage” of actual LPG mileage, deemed indicative of LPG “fuel energy conversion efficiency” relative to diesel, was calculated (based solely on fuel heating values and densities) for comparing actual mileage from both fuels. The LPG actual mileage in both on-road and laboratory tests was lower than diesel mileage. In on-road tests, the LPG actual mileage was lower than diesel actual mileage by about the same percentage LPG heating value was lower than diesel’s per liter of fuel.

Current trends in environmental and emissions regulations are driving changes in new engine systems, and increasing the need for more effectively sealed joints in exhaust systems. At the high temperatures in these exhaust systems it is difficult for traditional gaskets to provide an effective seal, as they degrade at high operating temperatures. This paper introduces a coating that has both excellent temperature stability and good compliance, thus forming an excellent sealing enhancement for metallic layers in exhaust system gaskets. Temperature stability data is presented along with sealing data, which illustrate the superior performance of this material compared to current systems.

Emissions from heavy-duty diesel vehicles have come under increased scrutiny with passage of the U.S. Clean Air Act Amendments of 1990. Methanol (M100) is seen as an important option for operators of transit fleets given the fuel's liquid nature and relative availability. This paper presents the results of a 36-month demonstration of a fleet of six methanol-powered transit buses equipped with DDC 6V-92TA engines. The engines were delivered in 1991 and were the first batch of Detroit Diesel engines certified to meet 1991 clean air standards. A similarly equipped control fleet of six diesel buses was tracked simultaneously. This paper includes an evaluation of bus operating data and emissions. Data such as fuel and oil consumption were collected along with a complete list of maintenance actions on both fleets. Chassis dynamometer emissions testing was carried out by Environment Canada at their River Road (Ottawa) test facility.

A software tool has been developed to aid designers and process engineers in the development and improvement of heat treat processes. This tool, DANTE™, combines metallurgical phase transformation models with mass diffusion, thermal and mechanical models to simulate the heating, carburization, quenching and tempering of steel parts. The technology behind the DANTE software and some applications are presented in this paper.

Paper describes analysis of the design process of modern automotive LPG and CNG containers. Over decade experience in the field of both computer based analysis as well as in the real conditions testing has been collected and presented in the paper. Authors present the potentials of modern FEM methodologies in the optimization and production of lightweight steel containers. It has been proved that the most sophisticated numerical analysis have to be followed by the construction verification, particularly considering direct exposure to fire. Bonfire test have become obligatory for both liquid and compressed gases containers. Properly chosen fire protection system, together with the adequate level of quality of materials applied for its production together with proper directing of the gas flowing out from safety devices are the essential factors defining gas containers fire safety.

This dictionary of terms was prepared for use by those with a need to describe and understand the dynamics and handling of two-wheeled, single track vehicles. It is intended to span the gap between vehicle dynamics specialists and those with a more general interest. This report is pertinent to such areas as vehicle design and development, the description of two-wheeler properties, rider training and education, and the preparation of standards and regulations. This report was prepared by the SAE Motorcycle Committee, which solicits suggestions for improvements and additions to be considered in future revisions. Comments should be directed to SAE Headquarters.

Stringent global emissions legislations demand effective NOx reduction strategies for both the engine as well as the aftertreatment. Diesel applications have previously applied Lean NOx Catalysts (LNCs) [1, 2], but their reduction efficiency and longevity have been far less than that of the competing ammonia-based SCR systems, such as urea [3]. A catalyst has been developed to significantly reduce NOx emissions, approaching 60% with ULSD and exceeding 95% with E85. Both thermal and sulfur aging are applied, as well as on-engine aging, illustrating resilient performance to accommodate necessary life requirements. A robust system is developed to introduce both ULSD from the vehicle's tank as well as E85 (up to 85% ethanol with the balance being gasoline) from a moderately sized supplemental tank, enabling extended mileage service intervals to replenish the reductant, as compared with urea, particularly when coupled with an engine-out based NOx reduction technology, such as EGR.